Turbomachine rotor blade milling machine system and method of field repairing a turbomachine rotor blade

ABSTRACT

A turbomachine rotor blade milling machine system includes a fixture having a body including first and second opposing surfaces and a slot. The fixture is configured and disposed to connect with first and second rotor blade sections mounted in a rotor wheel. A mounting system includes at least one mounting element coupled to one of the first and second opposing surfaces of the body at the slot. A milling machine is coupled to the one of the first and second opposing surfaces through the at least one mounting element. The milling machine includes a cutter and is configured and disposed to form an opening extending axially through a dovetail portion of a third rotor blade section arranged between the first and second rotor blade sections.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to the art of turbomachines and, more particularly, to a turbomachine rotor blade milling machine system and method.

Gas turbomachines include a compressor portion linked to a turbine portion through a common compressor/turbine shaft and a combustor assembly. An inlet airflow is passed through an air intake toward the compressor portion. In the compressor portion, the inlet airflow is compressed through a number of sequential stages toward the combustor assembly and the turbine portion. In the combustor assembly, a portion of the compressed airflow mixes with a fuel to form a combustible mixture. The combustible mixture is combusted in the combustor assembly to form hot gases. The hot gases are guided to the turbine portion through a transition piece. The hot gases expand through the turbine portion acting upon turbine blades mounted on wheels to create work that is output, for example, to power a generator, a pump, or to provide power to a vehicle. Over time, components such as compressor blades and turbine blades wear and/or become damaged necessitating repair and/or replacement.

BRIEF DESCRIPTION OF THE INVENTION

According to one aspect of an exemplary embodiment, a turbomachine rotor blade milling machine system includes a fixture having a body including first and second opposing surfaces and a slot. The fixture is configured and disposed to connect with first and second rotor blade sections mounted in a rotor wheel. A mounting system includes at least one mounting element coupled to one of the first and second opposing surfaces of the body at the slot. A milling machine is coupled to the one of the first and second opposing surfaces through the at least one mounting element. The milling machine includes a cutter and is configured and disposed to form an opening extending axially through a dovetail portion of a third rotor blade section arranged between the first and second rotor blade sections.

According to another aspect of the exemplary embodiment, a method of repairing a turbomachine rotor blade includes removing an airfoil portion of a first turbomachine rotor blade, a second turbomachine rotor blade and a third turbomachine rotor blade mounted to a rotor wheel, aligning a slot formed in a fixture with a root portion of the airfoil portion removed from the second turbomachine rotor blades, mounting the fixture to the first turbomachine rotor blade and the third turbomachine rotor blade with the root portion of the second turbomachine rotor blade aligned with the slot, positioning a cutter of a milling machine in the slot, securing the milling machine to the fixture, and guiding the cutter through a dovetail portion of the second turbomachine rotor blade to perform a repair of the turbomachine.

According to yet another aspect of the exemplary embodiment, a turbomachine includes a compressor portion including at least one compressor rotor wheel having a plurality of compressor rotor blades, and a turbine portion including at least one turbine rotor wheel having a plurality of turbine rotor blades. A turbomachine rotor blade milling machine system is mounted to one of the compressor rotor wheel and turbine rotor wheel. The turbomachine rotor blade milling system includes a fixture having a body including first and second opposing surfaces and a slot. The fixture is mounted to the one of the compressor rotor wheel and the turbine rotor wheel. A mounting system includes at least one mounting element coupled to one of the first and second opposing surfaces of the body at the slot. A milling machine is coupled to the one of the first and second surfaces through the mounting system. The milling machine includes a cutter and is configured and disposed to form an opening extending axially through a dovetail portion of a corresponding one of the plurality of compressor rotor blades and the plurality of turbine rotor blades.

These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF DRAWINGS

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a schematic view of a turbomachine including a blade milling system in accordance with an exemplary embodiment;

FIG. 2 is a perspective view of the blade milling system of FIG. 1 mounted to a compressor rotor wheel;

FIG. 3 is a perspective view of a fixture portion of the blade milling system of FIG. 2;

FIG. 4 is an axial end view of the blade milling system of FIG. 2;

FIG. 5 is a detail view of the compressor rotor wheel after removal of rotor blade airfoil portions;

FIG. 6 is a detail view of the fixture of FIG. 3 mounted to the rotor wheel of FIG. 5;

FIG. 7 is a detail view of the rotor wheel of FIG. 6 after cutting an axial slot into a dovetail portion of a rotor blade; and

FIG. 8 is a detail view of the rotor wheel of FIG. 7 illustrating a dummy dovetail member mounted in a dovetail slot after removal of the rotor blade.

The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION OF THE INVENTION

A turbomachine is indicated generally at 2 in FIG. 1. Turbomachine 2 includes a compressor portion 4 operatively coupled to a turbine portion 6 through a common compressor/turbine shaft 8. Compressor portion 4 is also fluidically connected to turbine portion 6 through a combustor assembly 10. Combustor assembly 10 includes one or more combustors 12. Combustors 12 may be mounted to turbomachine 2 in a wide range of configurations including, but not limited to, being arranged in a can-annular array. Compressor portion 4 includes a plurality of compressor rotor wheels indicated generally at 14. Rotor wheels 14 include a first stage compressor rotor wheel 16 having a plurality of first stage compressor rotor blades 18 each having an associated airfoil portion 19. Similarly, turbine portion 6 includes a plurality of turbine rotor wheels 22 including a first stage turbine wheel 24 having a plurality of first stage turbine rotor blades 26.

In accordance with an exemplary embodiment, turbomachine 2 includes a blade milling system 40 mounted to first stage compressor rotor wheel 16. As will become more evident below, blade milling system 40 is employed to remove frozen compressor rotor blades 18 from first stage compressor rotor wheel 16. More specifically, blade milling system 40 facilitates in field or in situ removal and repair of frozen rotor blades. Blade milling system 40 includes a fixture 44 and a milling machine 48. Fixture 44 serves as an interface between first stage compressor rotor wheel 16 and milling machine 48.

As best seen in FIGS. 2-4, fixture 44 includes a body 58 having a first surface 60 and an opposing, second surface 62 separated by a peripheral edge 63. First surface 60 is substantially planar while second surface 62 includes first and second radiused portions 64 and 65 that conform to an outer circumferential profile (not separately labeled) of first stage compressor rotor wheel 16. Fixture 44 includes a mounting section 70 and a guide section 74.

Mounting section 70 includes a plurality of mounting members 79-82 that take the form of recessed openings 84-87 respectively. Recessed openings 84 and 85 are spaced from recessed openings 86 and 87 by a rotor blade width. More specifically, recessed openings 84 and 85 are arranged to align with one rotor blade and recessed openings 86 and 87 are arranged to align with another rotor blade with a third rotor blade being centrally located therebetween as will be detailed more fully below. Guide section 74 extends substantially perpendicularly from mounting section 70 and includes a plurality of threaded openings 90-93. A slot 96 extends through guide section 74 to mounting section 70. Slot 96 is centrally located on fixture 44. Fixture 44 is also shown to include first and second handles 99 and 100 projecting from outer peripheral edge 63 on opposing sides (not separately labeled) of mounting section 70.

In further accordance with an exemplary embodiment, fixture 44 includes a mounting system 106 provided on guide section 74. Mounting system 106 includes first and second mounting elements 108 and 109. First mounting element 108 is secured to guide section 74 through mechanical fasteners (not separately labeled) that engage with threaded openings 90 and 91. Second mounting element 109 is secured to guide section 74 through mechanical fasteners (not separately labeled) that engage with threaded openings 92 and 93. Each mounting element 108 and 109 includes elongated openings or slots (also not separately labeled). Slots provide adjustability for mounting elements 108 and 109 on guide section 74. Mounting system 106 secures a milling machine guide member 116 to guide section 74.

Milling machine guide member 116 includes a first guide element 123 and a second guide element 124. First guide element 123 is coupled to guide section 74. First guide element 123 is also coupled to second guide element 124 through a dovetail interface 130. Dovetail interface 130 allows for a sliding, axial shifting of second guide element 124 relative to first guide element 123. Fixture 44 is also shown to include first and second axial alignment members 137 and 138. Axial alignment members 137 and 138 establish a desired axial alignment of fixture 44 relative to first stage compressor rotor wheel 16. As will be detailed more fully below, fixture 44 supports and aligns milling machine 48 to create an opening in rotor blade 18. More specifically, milling machine 48 is mounted to second guide element 124. Once in position, a cutter 147, mounted to a cutting head 149 of milling machine 48, extends through slot 96. Second guide element 124 is shifted axially over guide section 74 to move cutter 147 through rotor blade 18.

Reference will now follow to FIGS. 5-8 in describing a method of field repairing first stage compressor rotor wheel 16. Initially, first stage compressor rotor blades 18 a, 18 b and 18 c are cut off at root sections 160 a, 160 b and 160 c. More specifically, airfoil portions 19 a, 19 b, and 19 c are removed from each first stage compressor blade 18 forming root portions 160 a, 160 b, and 160 c respectively. It should be understood that generally, prior to mounting fixture 44, all airfoil portions 19 are removed. Once removed, openings 170 and 171 are formed in root portion 160 a. Similarly, openings 174 and 175 are formed in root portion 160 c. Fixture 44 may be used as a template for forming openings 170, 171 and 174, 175. After being formed, openings 170, 171, 174 and 175 are threaded. Fixture 44 is placed on first stage compressor rotor wheel 16 with mounting members 79 and 80 aligning with openings 170 and 171 and mounting members 81 and 82 aligning with openings 174 and 175 as seen in FIG. 6. In addition to aligning mounting members 79, 80 and 81, 82 with openings 170, 171 and 174, 175, alignment members 137 and 138 abut an axial surface of first stage compressor rotor wheel 16. Mechanical fasteners (not separately labeled) are passed through openings 170, 171 and 174, 175 into mounting members 79, 80 and 81, 82 respectively. After mounting fixture 44, milling machine 48 is connected to guide section 74 through milling machine guide member 116 (FIG. 2).

Milling machine 48 is activated and shifted axially across first stage compressor rotor wheel 16 causing cutter 147 to form an axial slot 188 through a dovetail portion 190 of rotor blade 18 b, as shown in FIG. 7. After forming axial slot 188, fixture 44 is unfastened and any remaining portion of rotor blade 18 b is removed from first stage compressor rotor wheel 16 leaving behind a dovetail slot 195. At this point, a dummy dovetail member 200 having threaded openings 204 and 205 is inserted into open dovetail slot 195 as shown in FIG. 8 and fixture 44 is reconnected to first stage compressor rotor wheel 16 to facilitate the removal of any remaining portion of first stage compressor rotor blade 18 c.

At this point it should be understood that the turbomachine rotor blade milling system in accordance with the exemplary embodiments facilitates an in-field removal of frozen, e.g., locked into position, rotor blades. Instead of removing and shipping a rotor wheel to a repair facility, which can cost upwards of a million dollars or more, the rotor wheel may now be repaired in place. It should also be understood that while described in terms of removing frozen rotor blades from a first stage of a compressor, the exemplary embodiment may be employed to remove rotor blades from rotor wheels positioned at any stage of a turbomachine compressor portion. Moreover, the exemplary embodiments may be employed to remove rotor blades from rotor wheels arranged in a turbomachine turbine portion. Further, while described as being joined to the rotor wheel through mechanical fasteners, other structure, such as magnets may also be employed. Magnets may also be employed to join the milling machine guide member to the fixture. In addition, while described as being employed to achieve in-field removal of frozen blades, the exemplary embodiments may also be employed out of the field in a repair shop for example.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. 

What is claimed is:
 1. A turbomachine rotor blade milling machine system comprising: a fixture including a body having first and second opposing surfaces and a slot, the fixture being configured and disposed to connect with first and second rotor blade sections mounted in a rotor wheel; a mounting system including at least one mounting element coupled to one of the first and second opposing surfaces of the body at the slot; and a milling machine coupled to the one of the first and second opposing surfaces through the at least one mounting element, the milling machine including a cutter and being configured and disposed to form an opening extending axially through a dovetail portion of a third rotor blade section arranged between the first and second rotor blade sections.
 2. The turbomachine rotor blade milling machine system according to claim 1, wherein the body includes a mounting section having a first mounting member configured and disposed to align with the first rotor blade section and a second mounting member configured and disposed to align with the second rotor blade section.
 3. The turbomachine rotor blade milling machine system according to claim 2, wherein the body includes a guide section extending substantially perpendicularly from the mounting section, the slot extending through each of the mounting section and the guide section.
 4. The turbomachine rotor blade milling machine system according to claim 1, wherein the other of the first and second opposing surfaces of the body includes at least one radiused portion configured and disposed to cooperate with a surface of the rotor wheel.
 5. The turbomachine rotor blade milling machine system according to claim 1, further comprising: a milling machine guide member mounted to the body through the at least one mounting element.
 6. The turbomachine rotor blade milling machine system according to claim 5, wherein the milling machine guide member includes a first guide element fixedly mounted to the body and a second guide element shiftably mounted to the first guide element, the milling machine being coupled to the second guide element.
 7. The turbomachine rotor blade milling machine system according to claim 6, wherein the second guide element is mounted to the first guide element through a dovetail interface.
 8. The turbomachine rotor blade milling machine system according to claim 1, further comprising: a dummy dovetail member configured and disposed to be mounted in an empty dovetail slot of the rotor wheel, the dummy dovetail member providing an interface between the fixture and the rotor wheel.
 9. A method of repairing a turbomachine rotor blade, the method comprising: removing an airfoil portion of a first turbomachine rotor blade, a second turbomachine rotor blade and a third turbomachine rotor blade mounted to a rotor wheel; aligning a slot formed in a fixture with a root portion of the airfoil portion removed from the second turbomachine rotor blade; mounting the fixture to the first turbomachine rotor blade and the third turbomachine rotor blade with the root portion of the second turbomachine rotor blade aligned with the slot; positioning a cutter of a milling machine in the slot; securing the milling machine to the fixture; and guiding the cutter through a dovetail portion of the second turbomachine rotor blade to perform a repair of a turbomachine.
 10. The method of claim 9, further comprising: removing any remaining portions of the second turbomachine rotor blade from the rotor wheel.
 11. The method of claim 9, further comprising: inserting a dummy dovetail member into a dovetail slot formed in the rotor wheel previously occupied by the second turbomachine rotor blade.
 12. The method of claim 11, further comprising: mounting the fixture to the dummy dovetail member and a fourth rotor blade with a root portion of the airfoil portion removed from the third turbomachine rotor blade being aligned with the slot.
 13. The method of claim 9, wherein removing the airfoil portion of the first turbomachine rotor blade, the second turbomachine rotor blade and the third turbomachine rotor blade mounted to a rotor wheel includes removing the airfoil portion from first, second, and third compressor rotor blades.
 14. The method of claim 13, wherein removing the airfoil portion of first, second and third compressor rotor blades includes removing the airfoil portion of first, second and third compressor blades provides on one of a first stage rotor wheel and a second stage rotor wheel.
 15. A turbomachine comprising: a compressor portion including at least one compressor rotor wheel having a plurality of compressor rotor blades; a turbine portion including at least one turbine rotor wheel having a plurality of turbine rotor blades; and a turbomachine rotor blade milling machine system mounted to one of the compressor rotor wheel and turbine rotor wheel, the turbomachine rotor blade milling machine system comprising: a fixture including a body having first and second opposing surfaces and a slot, the fixture being mounted to the one of the compressor rotor wheel and the turbine rotor wheel; a mounting system including at least one mounting element coupled to one of the first and second opposing surfaces of the body at the slot; and a milling machine coupled to the one of the first and second opposing surfaces through the mounting system, the milling machine including a cutter and being configured and disposed to form an opening extending axially through a dovetail portion of a corresponding one of the plurality of compressor rotor blades and the turbine rotor blades.
 16. The turbomachine according to claim 15, wherein the body is mounted to the a first stage compressor rotor wheel through first and second compressor rotor blade sections, the body includes a mounting section having a first mounting element configured and disposed to align with the first rotor blade section and a second mounting element configured and disposed to align with the second compressor rotor blade section.
 17. The turbomachine according to claim 16, wherein the body includes a guide section extending substantially perpendicularly from the mounting section, the slot extending through each of the mounting section and the guide section.
 18. The turbomachine according to claim 15, further comprising: a milling machine guide member mounted to the body through the at least one mounting element, the milling machine guide member including a first guide element fixedly mounted to the body and a second guide element shiftably mounted to the first guide element, the milling machine being coupled to the second guide element.
 19. The turbomachine according to claim 18, wherein the second guide element is mounted to the first guide element through a dovetail interface.
 20. The turbomachine according to claim 16, further comprising: a dummy dovetail member configured and disposed to be mounted in an empty dovetail slot of the one of the compressor rotor wheel and the turbine rotor wheel, the dummy dovetail member providing an interface between the fixture and the one of the compressor rotor wheel and the turbine rotor wheel. 